Fuel cell with electrode having an electrically conductive nano-column and production method thereof

Abstract

In a fuel cell including an electrolyte membrane and a pair of electrodes disposed on both sides of the electrolyte membrane, at least one of the electrodes has an electrically conductive nanocolumn that is oriented with an inclination of 60° or less with respect to a planar direction of the electrolyte membrane, a catalyst supported on the electrically conductive nanocolumn, and an electrolyte resin coating the electrically conductive nanocolumn.

The invention claimed is: 
     
       1. A fuel cell comprising:
 an electrolyte membrane; 
 a first electrode disposed on a surface of the electrolyte membrane; and 
 a second electrode which is disposed on another surface of the electrolyte membrane and which has a plurality of electrically conductive nanocolumns oriented in one direction with an inclination of 60° or less with respect to a planar direction of the electrolyte membrane, a catalyst supported on the electrically conductive nanocolumns, and an electrolyte resin coating the electrically conductive nanocolumns; 
 wherein the electrically conductive nanocolumns have, on an outer surface thereof, an amorphous layer; 
 wherein a thickness of the amorphous layer is greater than or equal to 0.5 nm and less than or equal to 10 nm; and 
 wherein portions of the electrically conductive nanocolumns that contact the electrolyte membrane are oriented with an inclination of 60° or less with respect to the planar direction of the electrolyte membrane. 
 
     
     
       2. The fuel cell according to  claim 1 , wherein an end of the electrically conductive nanocolumns is embedded in the electrolyte membrane. 
     
     
       3. The fuel cell according to  claim 1 , wherein a thickness of the amorphous layer is greater than or equal to 1 nm and less than or equal to 3 nm. 
     
     
       4. The fuel cell according to  claim 1 , wherein the electrically conductive nanocolumns are made of an electrically conductive material and have a column diameter greater than or equal to 5 nm and less than or equal to 50 nm, a length greater than or equal to 10 μm and less than or equal to 80 μm, and an aspect ratio greater than or equal to 500 and less than or equal to 10,000. 
     
     
       5. The fuel cell according to  claim 1 , wherein the electrically conductive nanocolumns are carbon nanotubes. 
     
     
       6. The fuel cell according to  claim 1 , wherein the plurality of electrically conductive nanocolumns are oriented in one direction with an inclination that is greater than or equal to 1° and less than or equal to 35° with respect to the planar direction of the electrolyte membrane. 
     
     
       7. The fuel cell according to  claim 6 , wherein the plurality of electrically conductive nanocolumns are oriented with an inclination that is greater than or equal to 10° and less than or equal to 30° with respect to the planar direction of the electrolyte membrane. 
     
     
       8. The fuel cell according to  claim 1 , wherein the electrolyte resin is a fluorine-based electrolyte resin. 
     
     
       9. The fuel cell according to  claim 8 , wherein the fluorine-based electrolyte resin is a perfluorocarbon sulfonic acid resin. 
     
     
       10. The fuel cell according to  claim 1 , wherein the electrolyte resin is a hydrocarbon polymer that has a proton conductive group in a side chain. 
     
     
       11. The fuel cell according to  claim 1 , wherein each of the electrically conductive nanocolumns is oriented with an inclination of 60° or less with respect to the planar direction of the electrolyte membrane.